Methods of manufacturing and installing a solar roof tile assembly

ABSTRACT

A method of manufacture of a photovoltaic solar roof tile assembly can include forming a laminated structure by laminating one or more sheets that include at least one photovoltaic solar cell, and attaching a junction box to the laminated structure to form a photovoltaic solar panel. The junction box can include a first DC connector and a second DC connector. Attaching the junction box to the laminated structure can include sealing the first DC connector to the laminated structure. The method of manufacture can include forming a roof tile with a hole that extends from a front side of the roof tile to a rear side of the roof tile, and locating the junction box in the hole by inserting the first DC connector from a front side of the roof tile and attaching the second DC connector from the rear side.

FIELD OF THE INVENTION

The present invention relates to a photovoltaic solar panel.

BACKGROUND OF THE INVENTION

Photovoltaic solar panels are known which absorb solar and ultra violet rays, transforming them into electrical energy.

Referring to FIG. 1 herein, there is illustrated schematically in perspective view an installation comprising a plurality of known solar roof tiles, integrated into an existing concrete tile roof. Each solar roof tile has a width of approximately 3 concrete roof tiles. To install the solar roof tiles, rows of individual roof tiles are removed, and the solar roof tiles are fitted to the rafters of the roof in place of the concrete roof tiles. Electrical connections to the solar roof tiles are passed through the water proof membrane of the roof, and the electrical connectors at the rear of each roof tile are connected into an electrical circuit within the loft of the roof. Alternatively, the electrical connectors can be connected together on top of the water impermeable membrane, and routed to the edge of the roof, so that a single electrical cable is fitted outside the building down to an electrical junction box at ground level.

Referring to FIG. 2 herein, there is illustrated schematically in detail, part of a solar roof tile as shown in FIG. 1 herein. The solar roof tile comprises a relatively thick sheet of substrate 200, for example made of a plastic sheet, of a thickness similar to the thickness of the adjacent concrete tiles. On top of the plastic substrate, are positioned a plurality of substantially square solar panels 201. On top of the solar panels, is positioned a glass or plastics cover sheet 202, which is held to the plastic substrate by a plurality of external clips 203 around the edges of the clear transparent plastics sheet.

Referring to FIG. 3 herein, there is illustrated schematically in perspective view, a pair of solar tiles as shown in FIGS. 1 and 2.

Referring to FIG. 4 herein, there is illustrated schematically in cross sectional view part of a known photovoltaic solar panel. The solar panel 400 comprises a back sheet 401; first and second encapsulation layers 402, 403; a photovoltaic cell 404; and an ultra-violet resistant glass or plastic screen front sheet 405, which protects the panel against mechanical impact and weathering.

The back sheet portion 401, of the photovoltaic solar panel 400 comprises two surfaces 406, 407, wherein the first surface 406 may be attached to the surface of a roof tile. The second surface of the back sheet portion 407 is adjacent to a first surface 408 of encapsulation layer 402; and a second surface 409 of first encapsulation layer 402 is in adjacent contact with the photovoltaic cell 404. The photovoltaic cell is also in adjacent contact with a first surface 410 of second encapsulation layer 403; and a second surface 411 of second encapsulation layer 403 is in adjacent contact with a first surface 412 of the front sheet 405.

The term “adjacent contact with” does not necessarily mean that the second surface of the encapsulation layer is in contact with a surface of the photovoltaic cell. A layer of encapsulation material may be used between the photovoltaic cell and the back sheet 401 and/or the front sheet 405

Polyethylene terephthalate PET is a known encapsulation material, which is used in solar panels to bond front and back sheets of the panel together by the process of lamination.

Lamination of solar cells with polyethylene-vinyl acetate films is conducted at about 150° C., and permits molten polyethylene-vinyl acetate to flow into voids in a solar panels to encapsulate the solar cell.

The current lifespan of PET solar panels is in the region of 5 to 10 years.

Known photovoltaic panels do not integrate well into the architecture of older, traditional buildings.

SUMMARY OF THE INVENTION

It is an object of the current invention to increase the efficiency and lifespan of current solar panels whilst providing a photovoltaic solar panel which can be easily integrated into various architectural surroundings.

According to a first aspect of the present invention, there is provided a photovoltaic solar panel for attachment to a roof tile configured with a through aperture, the panel comprising:

-   -   a rigid back plate;     -   a support sheet comprising at least one photovoltaic solar cell;     -   a negative and a positive connection extending from the or each         solar cell through a sealed aperture of the back plate and         accessible at the rear of the panel;     -   a diode connected to the positive connection;     -   an ultra-violet resistant front sheet for covering a front face         of the or each solar cell;     -   wherein the beck plate, support sheet and front sheet form a         sealed laminated structure.

Other aspects of are as recited in the claims herein.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the invention and to show how the same may be carried into effect, there will now be described by way of example only, specific embodiments, methods and processes according to the present invention with reference to the accompanying drawings in which:

FIG. 1 show schematically a known solar tile in a roof installation;

FIG. 2 shows schematically a detail of the known solar tile of FIG. 1 herein;

FIG. 3 shows schematically two known solar tiles prior to installation in a roof;

FIG. 4 is a schematic cut away view of a known photovoltaic solar panel;

FIG. 5 illustrates schematically a first embodiment solar panel and roof tile in exploded view;

FIG. 6 illustrates schematically in view from the front, a solar panel comprising the first embodiment solar tile;

FIG. 7 is an exploded view of a second embodiment photovoltaic solar panel and roof tile;

FIG. 8 is an enlarged view of a printed circuit board of the solar tile of FIG. 7 herein;

FIG. 9 is a perspective view of a cross-section taken along line ‘A’ In of the circuit board of FIG. 8:

FIG. 10 is a perspective view of an improved solar roof tile incorporating a solar panel disclosed herein;

FIG. 11 is a plan view of the improved solar roof tile of FIG. 10 herein;

FIG. 12 is a cross-section along plane ‘C’ of FIG. 11;

FIG. 13 is a close up view of one end of FIG. 12 herein;

FIG. 14 is an illustration of one stage of a photovoltaic solar panel manufacturing process;

FIG. 15 is an illustration of another stage of manufacture of the photovoltaic solar panel;

FIG. 16 illustrates schematically in view from the front, a solar cell comprising a solar panel described herein;

FIG. 17 illustrates schematically the solar cell of FIG. 16 in view from the near; and

FIG. 18 illustrates schematically circuit diagram for connecting a plurality of solar roof tiles as described herein before in a solar roof panel installation.

DETAILED DESCRIPTION OF THE EMBODIMENTS

There will now be described by way of example a specific mode contemplated by the inventors. In the following description numerous specific details are set forth in order to provide a thorough understanding. It will be apparent however, to one skilled in the art, that the present invention may be practiced without limitation to these specific details. In other instances, well known methods and structures have not been described in detail so as not to unnecessarily obscure the description.

There is disclosed herein a novel photovoltaic solar panel designed to be attached to the front face of proprietary concrete, clay, metal or plastic roof tile. The solar panel is capable of generating electricity and thus providing a solar tile. The solar tile may be fitted directly to a roof to form a flat roof surface. The apparatus is designed to fit to new and replacement roofs.

Referring to FIG. 5 herein, there is illustrated schematically in exploded view a first embodiment solar tile incorporating a novel solar panel.

The roof tile comprises a roof tile 500, which can be a cement, plastics or metal roof tile. The solar panel comprises a silicone based adhesive sealant layer 501; a fiber glass back plate 502; a sheet 503 comprising a one or a plurality of monocrystalline or polycrystalline solar cells each comprising one or more solar wafers; end an ultra-violet transparent plastics cover sheet 504.

The one or more solar cells we sandwiched between the clear cover sheet 504, on the side of the wafer which is exposed to sun light, and the fiber glass back plate 502 at the rear side, which is adjacent the roof tile 500. The silicone based adhesive sealant layer 501 sticks a rear surface of the fiber glass back plate 502 to a front surface of the roof tile 500. The fibre glass back sheet gives rigidity and support to the sheet 503 which contains the solar cells.

The solar panel further comprises electrical connections which are accessible at the rear of the roof tile, for connecting the solar panel to an electrical circuit. The electrical connections comprise a negative connector 505; a positive connector 506; a silicone based seal 507, which fits into an aperture in the roof tile 500 and surrounds a pair of positive and negative conductors 508, 509 respectively such that the connectors are spaced apart, and protected from the weather and moisture; each electrical conductor 508, 509 comprising a copper wire surrounded with an insulating plastic sheath; a diode 510 connected to a positive output of the solar cells 503 and to positive conductor 509; and first and second aluminum strips 511, 512 which respectively form electrical connectors to the solar cells of the sheet 503, the aluminum strips each being covered with a respective strip of insulating electrical tape, the first strip 511 being connected to the positive conductor 509 via diode 510, and the second aluminum strip 512 being connected to the negative conductor 508.

The clear or transparent plastics cover sheet 504, the solar wafer sheet 503, along with first and second aluminum strip conductors 511, 512, and the fiber glass back plate 502 form a sealed laminated unit, which is sealed against the ingress of moisture.

Referring to FIG. 6 herein, there is illustrated schematically in frontal view, an individual solar wafer. The solar wafer has general characteristics as follows.

In the example shown, a Monocrystalline P type boron doped silicone sheet has dimensions 156 mm height by 156 mm width. The Monocrystalline silicon wafer is grown by the CZ method. Electrical characteristics of the solar sheet are as follows:

Features General Characteristics Resistivity 1~3, 3~6 Ω · com Oxygen Content 1 × 10 18 atom/cm3 Carbon Content 1 × 10 17 atom/cm 3 Structural Characteristics Side 156.0 mm ± 0.5 mm Diameter 200.0 mm ± 0.5 mm Orientation <100> Thickness 180 ± 20 μm 200 ± 20 μm Mechanical Characteristics TTV ≤40 μm Bow ≤70 μm Surface No microcrystalline structure Saw Mark ≤15 μm

Whilst FIG. 6 shows a best mode embodiment monocrystalline silicon solar wafer, variations to the dimensions may be applied in other embodiments.

Referring to FIG. 7 herein a second embodiment photovoltaic solar panel 700, designed to be attached to the front surface of a roof tile 701, comprises a male plug DC connector 702, inserted from the front aide of the tile; a female plug 703 located in a hole drilled through said tile; a printed circuit board 704; a junction box 705, permanently sealed to the back of said circuit board: which houses a diode 706, which is connected to positive and neutral wires 707, 708, extending from the female plug 703; said wires are in turn connected to the circuitry of the circuit board 704.

A solar array 709 is provided and consists of a plurality of monocrystalline solar wafers 710 which are connected together in a bank of two rows.

The junction box is rated at 1000 dcV.

Each solar wafer 710 is situated on a layer of ethylene-vinyl acetate 711, which covers the surface of the printed circuit board 704.

Soldered aluminum drips 712 connect individual solar cells 710; the ends of said strips are folded over the top of the cells 710 to attach them to the circuit board 704.

The aluminum strips are covered by a strip of electrical tape and a sheet of ethylene-vinyl acetate 713. A layer of ethylene tetrafluoroethylene 714 covers the ethylene-vinyl acetate 713.

The total layered array is bound via lamination at a temperature range of 150° C. to 200° C., a vacuum pressure of 2 to 4 atmospheres for a period of 10 to 15 minutes.

Referring to FIG. 8 herein, the printed circuit board 704 comprises a substrate board 801, substantially rectangular in shape; negative and positive electrical conductive tracks 802, 803; and an aperture 804 which extends through the circuit board 704.

Referring to FIG. 9 there is shown a perspective view of a cross-section taken along line ‘A’ in FIG. 8, wherein, the aperture through the circuit board 704 is visible.

Referring to FIG. 10 herein there s shown a perspective view of a third embodiment improved solar roof tile and solar panel 1000, comprising a substantially rectangular, flat roof tile 1001, with first and second through tile apertures 1002, 1003, equidistant from a perimeter of the tile, and grooves 1004, 1005 on the extreme edges of the tile to enable attachment of the tile to a roof; and a substantially rectangular photovoltaic solar panel 1006, fixed to a front face of the roof tile the solar panel having area dimensions smaller than the area dimensions of a front face of the roof tile.

FIG. 11 is a plan view of an improved solar roof tile and panel 1000, shown in FIG. 10 herein, comprising a substantially rectangular, flat roof tile 1001, with through tile apertures 1002, 1003, equidistant from the perimeter of the tile and grooves on the extreme edges of the tile 1004 to enable attachment of the tile to a roof; and a substantially rectangular photovoltaic solar panel 1004, which is smaller than the dimensions of the roof tile.

Referring to FIG. 12 herein, there is shown a cross-section along plane ‘C’ of FIG. 11 in which the height of the roof tile 1001 extends beyond the height of the photovoltaic solar panel 1006, and in which the circle annotation denotes that the degree of overlap between the tile and the photovoltaic solar panel is variable and determined by the manufacturer.

Referring to FIG. 13 herein, in close up detail part of the cross section of FIG. 12, showing the laminate structure of the solar panel affixed to the front of the roof tile.

Referring to FIG. 14 herein, there is illustrated a view of one stage of a manufacturing process for making a solar panel and roof tile as described herein, in which a plurality of mono crystalline solar wafers 1401 are arranged on a circuit board 1402, on a layer of ethylene-vinyl acetate and are connected together by soldered aluminum wires 1402, in a bank of two rows. The soldered aluminum wires 1402 are covered by strips of electrical tape.

Referring to FIG. 15 herein, there is illustrated another manufacturing stage for manufacture of a solar panel as described herein. Each of a plurality of solar wafers 1500 in a row are connected together with an aluminum strip electrical connector 1501. The aluminum strip connector is covered with a strip of black electrically insulating and protective tape 1502.

Referring to FIG. 16 herein, there is illustrated schematically an individual solar wafer, having first and second electrical conductors 1601, 1602.

Referring to FIG. 17 herein, there is illustrated schematically the reverse side of the solar wafer shown in FIG. 16.

Referring to FIG. 18 herein, there is illustrated schematically a wiring diagram for connection of a plurality of individual solar roof panels in a solar roof tile installation.

An array of individual solar roof panels 1800 are arranged in rows and columns on a roof. Each individual solar panel has a positive conductor and a negative conductor as shown in FIGS. 5, 7 and 8 herein, with a diode on the positive conductor, so that when a negative conductor of a first solar panel is connected to a positive conductor of a second solar panel in a serial chain, there is a single one-way D.C. electrical path flowing through a chain of solar cells in series. The plurality of semi-conductor diodes ensure that current can flow in only one director through the chain of serially linked solar panels.

In FIG. 18, there are shown individual chains of solar panels 1801 to 1815. A respective positive terminal of each chain of solar panels are connected together to form a positive bus 1816, and similarly, a respective negative terminal of each chain of solar panels are connected together to form a negative bus 1817. The positive and negative buses supply current, via a direct current circuit breaker 1818, to an AC inverter, which converts the direct current output of the solar cells into a single phase alternating current electrical output. There is provided a surge protector 1820 which connects to earth, so that in the event of a high voltage or current spike experienced on the negative buses, these are grounded to earth. This provides protection from current and/or voltage surges during for example an electrical storm.

Conventional roof tile dimensions from different manufacturers vary. The height and width of the solar panel embodiments disclosed herein may be selected to match the size of roof tile. A minimum length and width of each panel is calculated to produce a minimum of 10 Watts each at peak sunlight, and is dependent on the available area of the roof tile. Most known roof tile areas will achieve this minimum power output. Larger sized roof tiles allow the solar call area to be increased, achieving a greater power output.

Each solar panel contains a diode on the positive circuit of its printed circuit board. Each solar tile is fitted to a roof using a known roofing method. The solar tiles are wired together in series to form a solar away. The solar array is connected through a combiner box and to an inverter.

The output of the solar array is dependent on the D.C. voltage range demanded by the inverter. The voltage is controlled by limiting the number of solar tiles wired in series. Each series or row of solar tiles has two final contact wires which are combined together through a suitable fuse to a positive and negative bus bar to form a parallel circuit with one positive and one negative output. These outputs are wired to an inverter.

Each solar cell within the solar panel is protected by an electrical diode within the series circuitry to minimize the effect of “shadowing” for example as the incident light on the solar cells vary due to cloud movements. If one solar cell is shadowed, its performance is reduced without affecting the performance of any adjacent solar cell. Similarly, if one solar panel is shaded by for example a tree, then its performance may be reduced compared to an adjacent solar panel which is in full sunlight. Due to the serial diodes, the shading of one solar cell does not affect the performance of adjacent solar cells.

The embodiments disclosed herein can be fitted to new or replacement roofs. Any individual failed solar panel s easily replaceable by a new solar roof tile. 

1-28. (canceled)
 29. A method of manufacture of a photovoltaic solar roof tile assembly, the method comprising: forming a laminated structure by laminating one or more sheets that include at least one photovoltaic solar cell, and attaching a junction box to the laminated structure to form a photovoltaic solar panel, the junction box comprising a first DC connector and a second DC connector, the second DC connector mateable to the first DC connector, wherein attaching a junction box to the laminated structure includes sealing the first DC connector to the laminated structure.
 30. The method of manufacture of claim 29, wherein forming a photovoltaic solar panel by laminating one or more sheets that include at least one photovoltaic solar cell, and attaching a junction box to the photovoltaic solar panel, includes forming a photovoltaic solar panel by laminating one or more sheets that include at least one photovoltaic solar cell, a support sheet, and a back plate, and sealing the first DC connector of the junction box to at least one of the support sheet and the back plate.
 31. The method of manufacture of claim 29, the method further comprising: forming a roof tile that includes a hole, the hole which extends from a front side of the roof tile to a rear side of the roof tile; and attaching the photovoltaic solar panel to a front surface on the front side of the roof tile, wherein attaching the photovoltaic solar panel to a front surface on the front side of the roof tile includes locating the junction box of the photovoltaic solar panel in the hole of the roof tile by inserting the first DC connector from the front side of the roof tile and attaching the second DC connector from the rear side.
 32. The method of manufacture of claim 31, wherein forming a roof tile that includes a hole, the hole which extends from a front side of the roof tile to a rear side of the roof tile includes drilling a hole in a roof tile, the hole which extends from a front side of the roof tile to a rear side of the roof tile.
 33. The method of manufacture of claim 32, wherein drilling a hole that extends from a front side of a roof tile to a rear side of the roof tile includes drilling a hole in a roof tile, the roof tile comprising at least one of concrete and clay.
 34. The method of manufacture of claim 29, wherein the first DC connector is a male plug DC connector and the second DC connector is a female plug DC connector.
 35. The method of manufacture of claim 29, wherein attaching a junction box to the photovoltaic solar panel includes forming an electrical connection between a positive conductor of the junction box and a positive output of the at least one photovoltaic solar cell, and forming an electrical connection between a negative conductor of the junction box and a negative output of the at least one photovoltaic solar cell.
 36. A method of installing a photovoltaic solar roof tile assembly on a roof to generate electricity comprising: providing a photovoltaic solar roof tile assembly comprising: a roof tile having a front side and a rear side and a hole extending through the tile; a circuit board having a front side and a rear side, the rear side of the circuit board facing the front side of the roof tile, a photovoltaic solar panel having a front side and a rear side, the rear side of the photovoltaic solar panel facing the front side of the circuit board, a junction located in the hole extending through the tile, wherein the junction comprises a first DC connector and a second DC connector, a female plug located in the hole in the roof tile, the female plug including a positive conductor and a negative conductor extending from both a first end and second end of the female plug, the positive and negative conductors extending from the first end comprising the second DC connector, wherein the first DC connector further comprises a positive conductor and a negative conductor, the positive conductor electrically connected to the positive output of the photovoltaic solar panel and the negative conductor electrically connected to the negative output of the photovoltaic solar panel, and wherein the positive conductor of the first DC connector is electrically connected to the positive conductor of the second DC connector extending from the first end of the female plug and the negative conductor of the first DC connector is electrically connected to the negative conductor extending from the first end of the second DC connector, the positive conductor and negative conductor extending from the second end of the female plug for connection to an electrical circuit, wherein the photovoltaic solar panel, circuit board and the first DC connector form a laminated structure, with the first DC connector sealed to the laminated structure, the first DC connector being accessible from the rear side of the roof tile and attachable and detachable from the second DC connector, and wherein one of the first DC connector and second DC connector include a diode; and installing the photovoltaic solar roof tile assembly on a roof.
 37. A method of manufacturing a photovoltaic solar roof tile assembly comprising: providing a roof tile having a front surface and a rear surface and a hole extending through the tile; attaching a printed circuit board to the front surface of the roof tile; covering a surface of the printed circuit board with a first layer of ethylene-vinyl acetate (EVA); providing a negative and a positive connection extending from the printed circuit board and accessible at the rear surface of the roof tile; permanently sealing a Junction box housing a diode connected to the positive connection on a back of the printed circuit board and a female plug located in the hole of the roof tile to receive a male plug connector insertable from the rear surface of the roof tile; covering a front face of the second EVA layer with an ultra-violet resistant front sheet comprising a layer of ethylene tetrafluoroethylene; wherein the printed circuit board, the photovoltaic solar cells, the EVA layers and the front sheet are laminated to form a sealed laminated structure prior to attachment to the roof tile; wherein the laminating of the printed circuit board, the photovoltaic solar cells the EVA layers and the front sheet is undertaken within a predetermined temperature range, a predetermined vacuum pressure and for a predetermined period of time.
 38. The method as claimed in claim 37, wherein the predetermined temperature range is 150° C. to 200° C., the predetermined vacuum pressure is 2 to 4 atmospheres (203 to 405 kPa, 2.03 to 4.05 bars) and the predetermined period of time is 10 to 15 minutes. 